1

EDITORIAL BOARD

R Parameswaran

W A Balakumaran

P Manoharan

G S Swaminathan

Printed at Sunitha Printers, Chennai – 600 002

VOL: 15 No. 4 OCTOBER – DECEMBER 2016

QUARTERLY JOURNAL OF SAFETY ENGINEERS ASSOCIATION

G1, Vinoth Foundations, 95/5, Sundaramurthy Gramani Street, Virugambakkam, Chennai-600092.

Tel : 044-2377 4060 E-mail: info@seaindia.org Website: www.seaindia.org

INDIAN SAFETY ENGINEERSEA (INDIA)

Inside... Page

Hazard and Operability Study

(HAZOP) 1

HAZOP Study & HAZOP

Review Procedure 3

Lack of maintenance, poor

communication fouled water

for 300,000 people 4

Preventing Diseases through

Healthy Environment 5

MP ranks highest in industrial,

toxic gas deaths 8

Eye Protection 9

Cryogenic Material 10

CASE STUDY

Flash Fire during charging of

Flammable Powder 12

Explosion of Reactor and Settler

Tank during Process

Troubleshooting 12

IN THE NEWS

OSHA issues rule to revise

beryllium regulations 14

E -Waste rising dangerously 14

(Regn No: 1391 / 2000)

[Registered under Societies Act, 1975]

Twodays Workshop on

HAZOP by SEA India

Mr P Bose, Director, Industrial Safety & Health, Govt ofTamilnadu, inaugurated the two days workshop on HAZOPconducted by SEA India at Chennai on 16th & 17th of December,2016.

2

The present day Safety System is based oninvestigation of the accidents to establish theroot cause or causes for the accident and alsoto identify any operational failures if any. Oncethe root causes are identified, the fault in thedesign or in the operational methods or humanerrors are f ixed and recti f ication processinitiated.

With this proactive methodology, we learn thepreventive measures through experience.Though this methodology is highly valuable, itcan be expensive in terms of human sufferingsand/or financial loss.

In order to avoid such problems, we need someform of Synthetic Experience which makes iteasy to spot the problems in prospect as it isin retrospect.

Hazard and Operability studies are one of theHazard Identification Techniques applied at thedesign, construction stage of a project. HAZOPshould also be conducted whenever a changein process parameter or alteration in the P & I(piping & Instrumentat ion) diagram iscontemplated. Hazop studies are carried out bya team of members, from various disciplinesfrom the plant. The team will be critically lookinginto the ways in which the plant can mal-functionor be mal-operated. For carrying out this studyin a systematic way, the team members will usea set of Guide Words and apply them at eachstage of the process parameters so as toanalyse the criticality with each step.

To impart thorough and indepth knowledge onHAZOP among the safety professionals, SEAindia conducted a two days Workshop onHAZOP at Chennai on December 16th and 17th

2016.

Thiru P Bose, Director, Industrial Safety andHealth, Government of Tamilnadu inauguratedthe workshop.

M/s W A Balakumaran and P Lakshminarayananconducted the twodays workshop dealing withoutline of HAZOP, case studies in processindustries, HAZOP illustrations, simulated andhands on exercises and conducting HAZOPStudy. Typical group excercises were alsoconducted among the participants.

HAZARD and OPERABILITY study (HAZOP)

A brief introduction on HAZOP by MrLakshminarayanan is given in this journal for thebenefit of SEA members as publication of entireproceedings is not possible. SEA India can takeup detailed training on HAZOP, suitable tospecific industry, SEA India has the expertise toconduct HAZOP studies on requests from themembers.

Around 40 safety professionals from variousparts of Tamilnadu participated in the workshopand appealed to have more such workshops infuture.

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HAZOP STUDY & HAZOP REVIEW PROCEDURE

HAZOP DEFINITION:

A Hazard and Operability

study (HAZOP) is a structured and

systematic examination of the

design of a New Project or Existing

process or operation in order to

identify and evaluate problems that

may produce or have risks to

personnel or equipment and

incorporate appropriate design

protection. HAZOP must be

carried out even in a successful

running operation when ever any

changes (addition/removal) are

done irrespective of the magnitude

of change.

OBJECTIVE:

The objective of a HAZOP

study is to review the integrity of

the design and identify any design

engineering issues (conditions

which could lead to hazardous

situations deviating from the

original design intent) that may

otherwise not have been found.

HAZOP REVIEW TEAM &

METHODOLOGY:

Team consist well experienced

multi-disciplines involved in the

design.

The technique is based on

breaking the overall complex

design of the process into a number

of small simpler sections called

'nodes' which are then individually

reviewed.

The review methodology uses

the “Guide Word” in accordance

with the guidelines published by

the Center for Chemical Plant

Safety (CCPS) of the American

Institute of Chemical Engineers

(AIChE). It is consistent with

Sections 2 and 3 of API 750

Recommended Practice; i.e.,

Mr. P Lakshminarayan, Safety Specialist.

Process Safety Information and

Process Hazard Analysis, in line

with the relevant international

standard (British Standard BS:

IEC61882: 2002 Hazard and

operability studies).

DRAWINGS REQUIRED FOR

HAZOP RIVEW STUDY:

The HAZOP review is carried

out based on the PFDs, plot plans,

P&IDs, Cause and Effect chart,

interlock table and other

PROJECT related drawings. The

P&IDs used for the HAZOP will

be fully mechanized and show all

instruments, check valves, safety

valves, controllers, pressure and

level switches that are included in

the limits of the supply. The P&ID

set used for the HAZOP review

will be marked “HAZOP Review

P&ID” and will be included in the

HAZOP report.

DOCUMENTS REQUIRED

FOR HAZOP RIVEW STUDY:

The latest issue of all the high

level documents of the design

basis, narratives and procedures

will be used for the HAZOP study.

These documents will be submitted

to the HAZOP team in advance so

that they may review them prior to

the HAZOP study.

HAZOP Review Procedure:

The HAZOP Review shall

cover all the process lines,

equipments and systems that are

part of, or may be affected by the

project facilities. This shall include

existing upstream and downstream

facilities that may be affected by

the new facilities like Process Lines,

Process Vessels, Process Equip-

ment, Off-Site Systems, Fire

Detection Systems, Fire Protection

Systems, ESD Systems, Isolation at

Battery Limits, Interface with other

Facilities. Standard key words like

More, Less, No, Reverse, Other

than are used for each parameter,

Composition and Others to assess

the safeguards in the design.

HAZOP team will list the

possible causes and the

consequences regarding the

operating condition, procedures

and the safety aspects from both

personnel and material point of

view. If the consequences are

considered as being out of the

normal operating range, the

HAZOP team will investigate the

installed safeguards, safety devices

installed, to limit the consequences

of the process upset and

recommend additional safeguards,

if required. Consideration of

transient operating conditions

during start-up, shutdown, plants

upset, emergencies, potential

exposure of employees to chemicals

during routine operations including

maintenance, decontamination

and ease of Maintenance.

The recommendations to the

identified concerns/issues or

hazards will be recorded and

presented in the form of HAZOP

report to ensure the overall

SYSTEMS and facilities are safe,

reliable, easy to operate and

maintain.

HAZOP document is

intended to be viewed as part of

the overall Project Specification

and must be read in conjunction

with the other documents relevant

to other Project documents like

SOR (statement of requirement

and SOW (Scope of work).

4

LACK OF MAINTENANCE, POOR COMMUNICATION

FOULED WATER FOR 300,000 PEOPLE

What can go wrong when an

aboveground tank used to store

harmful chemicals is not inspected

for 10 years?

Drinking water for 300,000

people can be contaminated, and

hundreds end up seeking care for

maladies ranging from rashes to

nausea.

The U.S. Chemical Safety

Board’s (CSB) final report into

the Jan. 9, 2014 release of

chemicals into the water source

for the Charleston, WV, area

concludes Freedom Industries

failed to inspect or repair

corroding tanks.

The spill occurred not far

away from West Virginia

American Water's intake in the

Elk River about 1.5 miles

downstream from the Freedom

facility.

The CSB says the water

company and local authorities

were unable to effectively

communicate the looming risks to

affected residents.

About 10,000 gallons of

crude methylcycloexanemethanol

(MCHM) mixed with propylene

glycol phenyl ethers (PPH) were

released into the Elk River.

Part of the poor

communication: Freedom initially

reported only 1,000 gallons of

crude MCHM had spilled. The

presence of PPH was not

mentioned at first either.

Freedom's inability to

immediately provide information

about the chemicals'

characteristics resulted in

significant delays before a “do not

use order” for water was issued to

the public.

The CSB found the MCHM

tanks were not internally

inspected for at least 10 years.

There was no comprehensive

aboveground storage tank law in

West Virginia. Months after the

spill, the state enacted its

Aboveground Storage Tank Act.

"My message here today is

what happened in Charleston was

preventable," said Vannessa Allen

Southerland, CSB's chairwoman,

in a press conference releasing the

report.

Among the lessons learned

highlighted in the CSB's report:

• Above ground storage tank

owners should regularly

inspect and monitor the

vessels and coordinate with

nearby water utilities and

emergency response

organizations to ensure they

provide adequate

information about their

stored chemicals for effective

planning in case of a leak,

and

• Public health agencies should

coordinate with water

utilities, emergency response

organizations and facilities

storing chemicals near

drinking water sources.

It does not take much tank

corrosion to create a situation like

the one in Charleston. CSB

investigators believe the leaked

chemicals flowed out of the tank

through two holes that were no

larger than pennies. The

chemicals flowed at about 11.5

gallons per minute, but the leak

was not detected for almost 24

hours.

The CSB's lead investigator

said regular inspections would

have found the corrosion.

5

PREVENTING DISEASES THROUGH HEALTHY ENVIRONMENT

The production and use of

chemicals continues to grow

worldwide, particularly in

developing countries. This is likely

to result in greater negative effect

on health, if sound chemicals

management is not ensured.

Multisectoral action is urgently

needed to protect human health

from the harmful effects of

improperly managed chemicals.

Air pollution

Indoor air pollution from solid

fuel use and urban outdoor air

pollution are estimated to be

responsible for 3.1 million

premature deaths world-wide every

year and 3.2% of the global burden

of disease. More than half of the

health burden from air pollution is

borne by people in developing

countries. Air pollutants have been

linked to a range of adverse health

effects, including respiratory

infections, cardiovascular diseases

and lung cancer. Reduction of air

pollution levels will decrease the

global burden of disease from these

illnesses. Pollution prevention

requires policies on air quality and

transport, air pollution control

regulations in cities, emission

controls in industry and promotion

of clean, renewable energy sources.

Interventions to reduce indoor air

pollution include switching from

home use of solid fuel to cleaner

fuels and technology and

ventilation in homes, schools and

the working environment, and

stopping smoking. Efforts to

significantly reduce air pollutants

will also help to decrease

greenhouse gas emissions and

mitigate the effects of global

warming.

The following TEN chemicals

need special consideration to

control the impact on the human.

Arsenic

Soluble inorganic arsenic is

acutely toxic. Intake of inorganic

arsenic over a long period can lead

to chronic arsenic poisoning

(arsenicosis). Effects, which can

take years to develop depending on

the exposure level, include skin

lesions, peripheral neuropathy,

gastrointestinal symptoms,

diabetes, renal system effects,

cardiovascular diseases, and cancer.

Organic arsenic compounds, which

are abundant in seafood, are less

harmful to health, and are rapidly

eliminated by the body. Human

exposure to elevated levels of

inorganic arsenic occurs mainly

through the consumption of

groundwater containing naturally

high levels of inorganic arsenic,

food prepared with this water, and

food crops irrigated with high

arsenic water sources. In one

estimate, arsenic-contaminated

drinking-water in Bangladesh

alone was attributed 9,100 deaths

and 125,000 Disability Adjusted

Life Years (DALYs) in 2001.

Reduction in human exposure

to arsenic can be achieved by

screening of drinking-water

supplies, clearly identifying those

delivering water above the WHO

guideline 10 g arsenic per litre or

national permissible limits,

together with awareness-raising

campaigns. Mitigation options

include use of alternative

groundwater sources, use of

microbiologically safe surface water

(e.g. rainwater harvesting), or use

of arsenic removal technologies.

Asbestos

Most types of asbestos cause

lung cancer, mesothelioma, cancer

of the larynx and ovary, and

asbestosis (fibrosis of the lungs).

Exposure to asbestos occurs

through inhalation of fibres in air

in the working environment,

ambient air in the vicinity of point

sources such as factories handling

asbestos, or indoor air in housing

and buildings containing friable

(crumbly) asbestos materials.

Currently about 125 million people

in the world are exposed to

asbestos at the workplace. In 2004,

asbestos-related lung cancer,

mesothelioma and asbestosis from

occupational exposures resulted in

107,000 deaths and 1,523,000

DALYs. In addition, several

thousands of deaths can be

attributed to other asbestos-related

diseases, as well as to

nonoccupational exposures to

asbestos. Elimination of asbestos-

related diseases should take place

through the following public health

actions: a) recognizing that the

most efficient way to eliminate

asbestos-related diseases is to stop

the use of all types of asbestos; b)

replacing asbestos with safer

substitutes and developing

economic and technological

mechanisms to stimulate its

replacement; c) taking measures to

prevent exposure to asbestos in

place and during asbestos removal

(abatement), and; d) improving

early diagnosis, treatment, social

and medical rehabilitation of

asbestos-related diseases and

establishing registries of people

with past and/or current exposures

to asbestos.

(Contd. on next page)

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Preventing ....(Contd. from previous page)

Benzene

Human exposure to benzene

has been associated with a range of

acute and long term adverse health

effects and diseases, including

cancer and aplastic anaemia.

Exposure can occur occupationally

and domestically as a result of the

ubiquitous use of benzene-

containing petroleum products

including motor fuels and solvents.

Active and passive exposure to

tobacco smoke is also a significant

source of exposure. Benzene is

highly volatile and exposure occurs

mostly through inhalation.

Interventions to reduce both work

and general population exposure

include promoting the use of

alternative solvents in industrial

processes, developing and

implementing policies and

legislation to remove benzene from

consumer products, discouraging

domestic use of benzene-

containing products, stopping

smoking, and promoting building

codes requiring detached garages.

Cadmium

Cadmium exerts toxic effects

on the kidney, the skeletal and the

respiratory systems, and is classified

as a human carcinogen. It is gen-

erally present in the environment

at low levels; however, human ac-

tivity has greatly increased those

levels. Cadmium can travel long

distances from the source of emis-

sion by atmospheric transfer. It is

readily accumulated in many or-

ganisms, notably molluscs (like

oysters) and crustaceans (like crab,

lobster). Lower concentrations are

found in vegetables, cereals and

starchy roots. Human exposure

occurs mainly from consumption of

contaminated food, active and pas-

sive inhalation of tobacco smoke,

and inhalation by workers in the

non-ferrous metal industry. Inter-

ventions to reduce global environ-

mental cadmium releases and oc-

cupational and environmental ex-

posure include increased recycling

of cadmium, minimizing emissions

and discharges from activities such

as mining and waste management,

promoting safe working conditions

for workers manipulating cadmium

containing products, and stopping

smoking.

Dioxins & dioxin-like

substances

Dioxins and dioxin-like

substances, including PCBs

(Polychlorinated Biphenyls), are

persistent organic pollutants

(POPs) covered by the Stockholm

Convention. They can travel long

distances from the source of

emission, and bioaccumulate in

food chains. Human exposure to

dioxins and dioxin-like substances

has been associated with a range of

toxic effects, including

immunotoxicity, developmental

and neurodevelopmental effects,

and changes in thyroid and steroid

hormones and reproductive

function. Developmental effects

are the most sensitive toxic

endpoint making children,

particularly breast-fed infants, the

population most at risk. These

substances are byproducts of

combustion and various industrial

processes, such as chlorine

bleaching of paper pulp and

smelting. While manufacture of

PCBs should have been

discontinued, release into the

environment still occurs from

disposal of large scale electrical

equipment and waste. Human

exposure to dioxin and dioxin-like

substances occurs mainly through

consumption of contaminated

food. Actions to reduce emissions

of these substances are required by

the Stockholm Convention.

Interventions to reduce human

exposure include identifying and

safely disposing of material

containing or likely to generate

dioxin and dioxin-like substances

such as electrical equipment,

ensuring appropriate combustion

practices to prevent emissions,

implementing FAO/WHO

strategies to reduce contamination

in food and feed, and monitoring

of food items and human milk.

Inadequate or excess fluoride

Fluoride intake has both

beneficial effects - in reducing the

incidence of dental caries (tooth

decay) - and negative effects - in

causing enamel and skeletal

fluorosis following prolonged high

exposure. The ranges of intakes

producing these opposing effects

are not far apart. Public health

actions are needed to provide

sufficient fluoride intake in areas

where this is lacking, so as to

minimize tooth decay. This can be

done through drinking water

fluoridation, or, when this is not

possible, through salt or milk

fluoridation. Excessive fluoride

intake usually occurs through the

consumption of ground water

naturally rich in fluoride, or crops

that take up fluoride and are

irrigated with this water. Such

exposure may lead to crippling

skeletal fluorosis, which is

associated with osteosclerosis,

calcification of tendons and

ligaments and bone deformities.

While the global prevalence of

dental and skeletal fluorosis is not

entirely clear, it is estimated that

excessive fluoride concentrations

in drinking water have caused tens

of millions of dental and skeletal

(Contd. on next page)

7

Preventing ....(Contd. from previous page)

fluorosis cases world-wide over a

range of years. Although removal

of excessive fluoride from drinking-

water may be difficult and

expensive, low-cost solutions that

can be applied at a local level do

exist. It is important that local

authorities consider the causes of

fluorosis carefully and choose the

best and most appropriate means of

dealing with excess fluoride

exposure taking into account the

local conditions and sensitivities.

Lead

Lead is a toxic metal whose

widespread use has caused

extensive environmental

contamination and health

problems in many parts of the

world. It is a cumulative toxicant

that affects multiple body systems,

including the neurologic,

hematologic, gastrointestinal,

cardiovascular, and renal systems.

Children are particularly

vulnerable to the neurotoxic

effects of lead, and even relatively

low levels of exposure can cause

serious and in some cases

irreversible neurological damage.

Lead exposure is estimated to

account for 0.6% of the global

burden of disease, with the highest

burden in developing regions.

Childhood lead exposure is

estimated to contribute to about

600,000 new cases of children with

intellectual disabilities every year.

Recent reductions in the use of

lead in petrol, paint, plumbing and

solder have resulted in substantial

reductions in blood lead levels.

However, significant sources of

exposure still remain, particularly

in developing countries. Further

efforts are required to continue to

reduce the use and releases of lead

and to reduce environmental and

occupational exposures,

particularly for children and

women of child-bearing age.

Interventions include eliminating

non-essential uses of lead such as

lead in paint, ensuring the safe

recycling of lead-containing waste,

educating the public about the

importance of safe disposal of lead-

acid batteries and computers, and

monitoring of blood lead levels in

children, women of child-bearing

age and workers.

Mercury

Mercury is toxic to human

health, posing a particular threat to

the development of the child in

utero and early in life. Mercury

exists in various forms: elemental

(or metallic); inorganic (e.g.

mercuric chloride); and organic

(e.g., methyl- and ethylmercury),

which all have different toxic

effects, including on the nervous,

digestive and immune systems, and

on lungs, kidneys, skin and eyes. It

has been estimated that among

selected subsistence fishing

populations, between 1.5/1000 and

17/1000 children showed cognitive

impacts caused by the

consumption of fish containing

mercury. Mercury releases in the

environment result mainly from

human activity, particularly from

coal-fired power stations,

residential heating systems, waste

incinerators and as a result of

mining for mercury, gold and other

metals. Once in the environment,

elemental mercury is naturally

transformed into methylmercury

that bioaccumulates in fish and

shellfish. Human exposure occurs

mainly through inhalation of

elemental mercury vapors during

industrial processes and through

consumption of contaminated fish

and shellfish. Interventions to

prevent environmental releases

and human exposure include

eliminating the use of mercury

wherever possible, promoting the

development of mercury-free

alternatives e.g. for manometers

and thermometers, ensuring proper

disposal of mercury-containing

devices, and implementing safe

handling, use and disposal of

mercury-containing products and

waste.

Highly hazardous pesticides

Highly hazardous pesticides

may have acute and/or chronic

toxic effects, and pose particular

risk to children. Their widespread

use has caused health problems

and fatalities in many parts of the

world, often as a result of

occupational exposure and

accidental or intentional

poisonings. Available data are too

limited to estimate the global

health impacts of pesticides,

however the global impact of self-

poisoning (suicides) from

preventable pesticide ingestion has

however been estimated to amount

to 186,000 deaths and 4,420,000

DALYs in 2002. Environmental

contamination can also result in

human exposure through

consumption of residues of

pesticides in food and, possibly,

drinking water. While developed

countries have systems already in

place to register pesticides and

control their trade and use, this is

not always the case elsewhere.

Guidance and legal frameworks on

the use, management and trade of

pesticides, as well as proper storage

and handling, are available from

international organizations and

international conventions; these

should be implemented globally.

8

MP RANKS HIGHEST IN INDUSTRIAL, TOXIC GAS DEATHS

Madhya Pradesh ranks

highest in terms of deaths due to

industrial accidents and

inhalation of toxic fumes, a recent

report by the National Crime

Records Bureau on accidental

casualties and suicides in India

has revealed.

The report said 213 people

died in industrial accidents

through 2015, of which 55 – the

highest count – occurred in

Madhya Pradesh. It was followed

by Gujarat with 31 deaths,

Rajasthan with 28, Uttar Pradesh

with 23, and Chhattisgarh with

17.

Surprisingly, Madhya Pradesh

had occupied the sixth position

with just 12 cases in 2014.

The state also topped the list

of deaths due to inhalation of

toxic gases, with at least 116 such

cases being registered in 2015. It

was followed by Tamil Nadu with

99 deaths, Gujarat with 51,

Andhra Pradesh with 37, and

Rajasthan with 23. The total

number of such casualties across

the country stood at 394.

Madhya Pradesh had

registered just 14 such cases in

2014, occupying the eighth

position.

This comes as a blow to the

reputation of the state, which had

witnessed the infamous Union

Carbide gas leak in 1984. While

the official death count of that

disaster stood at 5,000, rights

activists pegged it between 20,000

and 25,000 victims.

Directorate of Industrial

health and Safety (Madhya

Pradesh) director PD Narya told

HT that the department was

doing its best to curtail industrial

accidents in the state. “We have

just 20 officers to handle 51

districts of the state. Despite the

staff shortage, we regularly visit

industrial units to spread

awareness on safety measures.

Apart from this, we work in

tandem with the Disaster

Management Institute in Bhopal

to find ways to curb industrial

accidents,” he said.

Narya said a possible reason

for the rise in industrial casualties

might be the inclusion of cases

under the Building Construction

Enforcement (BCE) Act. “The

BCE Act is being implemented

more stringently in the state now.

Cases that occur under it are also

considered industrial accidents,”

he added.

DEATHS DUE TO

INDUSTRIAL ACCIDENTS

IN 2015

1. Madhya Pradesh - 55

2. Gujarat - 31

3. Rajasthan - 28

4. Uttar Pradesh - 23

5. Chhattisgarh - 17

Total deaths in India - 213

DEATHS DUE TO

INHALATION OF TOXIC

GASES IN 2015

1. Madhya Pradesh - 116

2. Tamil Nadu - 99

3. Gujarat - 51

4. Andhra Pradesh - 37

5. Rajasthan - 23

Total deaths in India - 394

9

EYE PROTECTION

A mechanic was using a

hammer and chisel to remove a bit

from the blade of a road grader. As

he struck the chisel with the

hammer, a sliver of metal broke off

the chisel and became embedded

in the mechanic’s safety glasses.

The mechanic was not injured.

Workers are regularly exposed

to work place hazards that pose

dangers to their eyes. Eye injuries

are most often caused by:

• Flying objects

• Chemical splashes, vapors or

dust

• Being stuck by or bumping

into an object

• Sparks or molten metal and

other hot liquid splashes

• Light radiation from welding

Studies show that 90% of

workplace eye injuries can be

prevented when proper eye

protection is worn. Most injuries

occur when a worker is not

wearing eye protection at the time

of the accident. In other instances,

workers were wearing eye

protection but the eyewear did not

adequately protect against the

specific hazard involved.

BEST PRACTICES

• Wear properly rated and

properly maintained

Protective Eyewear before

working in an area were flying

particles may be present;

welding, cutting, working

with molten metal, working

near grinding wheels, riding

in open mantrips, or working

in any other area where eye

hazards may be present

• Ensure eyewear fits properly

and comfortably

• Use safety eyewear that

provides the maximum

protection against the specific

hazard

• Ensure eyewear fits properly

and comfortably

• Inspect protective eyewear

regularly and replace it if a

defect or damage is found

• Store protective eyewear

where it would not become

scratched or damaged, and

keep it clean

• Step away from a potential

hazard if protective eyewear

is removed for cleaning

• Use antifog material on

protective eyewear.

10

CRYOGENIC MATERIAL

Definition

Cryogenic liquids have

boiling points of less than -90º C

(-130º F) at 14.7 psia (1 bar). All

cryogenic liquids are gases at

normal temperatures and

pressures. When cooled and

placed under pressure in specially

designed systems or storage

containers, the gases condense to

a liquid state and maintain very

cold temperatures.

Types of Cryogens & Hazards

Various gases can be used as

cryogenic liquids. The most

common cryogens used are

nitrogen and helium, which are

odorless and colorless. Both liquid

helium and nitrogen are simple

asphyxiants. Therefore, they do

not have associated permissible

exposure limits (PELs) or

threshold limit values (TLVs).

The hazards associated with these

cryogenic liquids are contact with

the skin or eyes, which causes

frostbite; and displacement of

oxygen from the room, which can

create an atmosphere that is

insufficient to support life. While

inert, rapid release of cryogenic

liquids can condense oxygen in

the air thereby creating a localized

oxygen-enriched atmosphere.

This localized oxygen-rich

atmosphere may pose a fire risk in

the presence of organic matter

and an ignition source.

Less common cryogens, such

as propane, hydrogen, and

oxygen, present risk of fire due to

their inherent flammability, while

others are toxic. Consult the

Material Safety Data Sheet

(MSDS) for the particular

cryogenic liquid being used for a

complete discussion of associated

hazards.

Cryogen Containers

Cryogenic liquids are generally

shipped in low-pressure, vacuum-

insulated, multi-walled

containers; and may be

transferred to non-pressurized

containers for everyday use. The

vacuum-insulated wall design is

intended to keep the surrounding

heat away from the liquid

contained in the vessel. All

containers will “leak”. Heat which

causes the liquid to slowly change

to a gas thereby creating pressure.

As the gas exits the container

(through a pressure release valve

or loose fitting lid), a visible fog

and/or frosting on the container

will be seen. Shipping containers

are equipped with pressure relief

valves and rupture disks that vent

excess pressure. Holding

containers such as dewar flasks

are equipped with loose fitting lids

to allow excess pressure to vent.

These pressure venting features

are critical to the safe operation of

cylinders and containers.

• Liquid dewar flasks. Liquid

dewar flasks are non-pressurized,

vacuum-jacketed vessels. Dewars

are equipped with loose fitting

caps or plugs. Dewars are available

in sizes ranging from 5 to 200

Litres.

• Liquid cylinders. Liquid

cylinders are low-pressure,

stationary or portable, and are

specifically designed for cryogenic

liquids. Cylinders are available in

sizes ranging from 80 to 450

Litres. Cylinders designed for

liquid withdrawal and generally,

operate at less than 20 psig.

Cylinders designed for gas

withdrawal generally operate in

the range of 5-150 psig.

Safe Work Practices

• Contact of the skin with

cryogens or items that have

been supercooled by a

cryogen can cause severe

burns or frostbite.

• Wear eye protection and a

face shield when opening

valves, dispensing cryogenic

liquids, or placing items into

or removing items from a

cryogen. Remove jewelry or

other items that could trap

spilled liquids against the

skin. Use thermal or leather

gloves when touching items

that have been in contact

with cryogens. Use tongs to

remove or place items into

cryogenic liquids. Splattering

will occur anytime an item is

placed into or removed from

a cryogenic liquid. Items

removed from a cryogen will

change temperatures/

pressures very rapidly, which

can result in container failure

sending shards of plastic

everywhere. Thus, eye and

face protection is critical. Use

potholders when opening

valves or dispensing

cryogens. If eye or skin

contact with frostbite occurs,

remove restrictive clothing,

flush the affected area with

(Contd. on next page)

11

tapped (Not Hot) water and

seek medical attention. Do

not rub the affected area or

use dry heat to warm.

• Cryogenic gases can cause

asphyxiation by displacing

oxygen in the air because of

their very large expansion

ratios (700 – 900). As an

example, an abrupt release of

only 3 liters of liquid nitrogen

in a 12x12x8 room would

result in an oxygen deficient

atmosphere (</= 19.5%

oxygen)1. Indoor use,

storage, and dispensing areas

should be mechanically

ventilated (minimum of six

air changes per hour). Passive

ventilation is not

recommended. An oxygen

sensor and alarm (or sensor

specific to the gas in use)

should be used in areas

where the size of the largest

container exceeds the

available room capacity to

the extent that an oxygen

deficient atmosphere could

occur in the event of a

release; and in areas

equipped with stationary

containers that are filled

from a delivery truck and the

equipment is not vented to

the outdoors. Oxygen

sensors/alarms are

recommended for gases that

are simple asphyxiants and

that do not have good

warning properties (i.e.,

odor). Specific gas monitors/

alarms are recommended for

gases that present other

hazards (i.e., toxic,

flammable).

• Pre-plan for spills.

• Know the maximum amount

that can be spilled or released

in the area without creating

an oxygen deficient

atmosphere or other hazard

(i.e., fire, toxic atmosphere,

etc.). If a spill occurs that

exceeds this amount,

immediately leave the area,

shut doors, and contact the

notified Operator. If the

amount spilled or released is

such that it could impact

nearby areas or create a

secondary hazard of fire or

toxicity, initiate building

evacuation procedures.

• If the amount is small and

does not create a secondary

hazard, ensure ventilation of

the area, and notify the

notified Operator. If it is safe

to do so and a fume hood is

nearby, the cylinder or

container can be located in

or in front of the operating

hood to assist with

ventilation.

• Pressure relief valves on

cylinders serve an important

safety function- they allow

gases to escape to prevent

over-pressurization. Do not

block, seal, or otherwise

tamper with the valves. Caps

on dewars are designed to be

loose-fitting to allow for gases

to escape. Never completely

seal a dewar.

• Never use a thermos bottle

or other device that has not

been specifically designed for

cryogenic service.

• When working with

cryogenic liquids, ensure that

equipment is scrupulously

clean. Greases, waxes, or

other impurities could react

with the liquid/gas or

condensed room oxygen to

cause a fire. Use and store

cryogens away from ignition

sources.

• Store and move cylinders

only in an upright position.

Do not drop, tip, or roll

containers. Use mechanical

handling devices for safely

moving large containers and

secure the container during

transport.

• Avoid transporting

containers or cylinders in a

passenger elevator.

• Recognize that many

materials can become brittle

and prone to failure in

contact with the extremely

cold temperatures of

cryogens.

• Use only cryogenic storage

vials that are designed

specifically for this purpose,

and visually inspect each vial

prior to use to ensure that

there are no defects. Do not

reuse vials.

• Allow vials and other

containers that have been in

contact with cryogens to

warm slowly to minimize

sudden pressure differentials.

• Placard use and storage areas

in accordance with the EHS

SOP, Door Posting for

Emergency Purposes. Label

cylinders and dewars with

“Cryogenic gas/liquid” and

the name of the product (i.e.,

Liquid Nitrogen).

Cryogenic ....(Contd. from previous page)

12

Causal Analysis

Evaluation of loss • One worker injured

Type of contact • Flash fire

Immediate cause(s) • Introduction of sparks into a flammable atmosphere

Basic cause(s) • Failure to conduct risk assessment

Failure of OSHMS • Hazard identification, risk assessment and risk control

• Operating procedures and safe work practices

• Consultation and communication

• Control of hazardous substances

CASE STUDY

CASE STUDY 1:

FLASH FIRE DURING

CHARGING OF FLAM-

MABLE POWDER:

Description of Incident

An operator was pouring a sack of

chemical powder manually into

the hopper of a blending machine.

The charging process took place

while a welder was installing a

product specification board (sign

board) within the vicinity of the

hopper. When the welder started

a test spark, a spark fell into the

hopper and a flash fire occurred.

The operator who was loading the

chemical powder suffered burns

and sustained cuts while escaping

from the fire.

Possible Causes and Contribut-

ing Factors

Medium

• The chemical powder being

charged into the hopper was

flammable.

Management

• There was no PTW issued for

this hot work to ensure that

the necessary checks were

made before commencing the

welding works.

• There was no enclosure to iso-

late the welding sparks from

the hopper.

• Proper means of communica-

tion (e.g., via walkie-talkies)

were not provided to the

workers.

Recommendations and Learning

Points

• Conduct a general workplace

risk assessment to identify all

sources of flammable material.

• A PTW must be issued to en-

sure that the necessary

worksite checks are made, a

gas test is performed and the

work has been authorised be-

fore any hot work is allowed to

proceed.

• Set up a fire blanket enclosure

around the hopper opening to

shield against sparks generated

from any nearby welding

works.

• Improve communication and

coordination between differ-

ent teams of workers by pro-

viding walkie-talkies or por-

table radio handsets to the

workers.

• Equip all workers handling

flammable substances with

suitable PPE (e.g., a fire retar-

dant uniform) for basic protec-

tion against fire.

CASE STUDY 2:

EXPLOSION OF REACTOR

AND SETTLER TANK DUR-

ING PROCESS TROUBLE-

SHOOTING:

Description of Incident

Several workers were carrying out

troubleshooting on process line

no. 1. The pump supplying hydro-

gen peroxide (H2O2) to process

line no. 1 was still in operation.

The same pump supplied hydro-

gen peroxide to process line no. 2

as well. There was a valve located

after the pump that controlled the

supply of hydrogen peroxide to a

reactor via process line no. 2. As

the valve was not fully isolated,

the hydrogen peroxide reacted

with the remnants inside the re-

actor and downstream settler tank

which caused an explosion. The

explosion ripped off the shell of

the reactor and the top of the

settler tank. None of the workers

were injured in this incident as

they were working at the other

(Contd. on next page)

13

end of the production building.

Possible Causes and Contribut-

ing Factors

Medium

• Hydrogen peroxide reacted

exothermically with the rem-

nants (concentrated sulphuric

acid, H2SO4, and isopropanol,

(CH3)2 CHOH in both the

reactor and settler tank, re-

sulting in an increase in the

system pressure.

Machine

• The cooling water jacket of

the reactor was not in opera-

tion as the reactor was shut

down. As such, the tempera-

ture increase in the reactor

could not be controlled.

• The relief vents for both the

reactor and settler tank were

inadequately sized to relieve

the rising pressure in each

vessel.

Man

• The workers failed to ensure

that the isolation valve was

fully closed.

Case Study ....(Contd. from previous page)

Causal Analysis

Evaluation of loss • Property damage

Type of contact • Explosion

Immediate cause(s) • Over-pressurisation of process vessels

Basic cause(s) • Failure to ensure positive isolation of critical valve

Failure of OSHMS • Process safety information

• Hazard identification, risk assessment and riskcontrol

• Operating procedures and safe work practices

• Some of the workers involved

in the troubleshooting were

unaware that the same pump

supplied hydrogen peroxide to

the reactor via process line no.

2 as well.

• The workers did not know

that sulphuric acid and hydro-

gen peroxide were incompat-

ible and should not be mixed.

Management

• The management failed to

carry out a thorough Hazard

and Operability (HAZOP)

study and a Quantitative Risk

Assessment (QRA) on the re-

actor and associated process

lines.

• There was a lack of instru-

mentation for the monitoring

of key process parameters like

process temperature, system

pressure, vessel liquid level,

etc.

• Proper means of communica-

tion (e.g., via walkie-talkies)

were not provided to the

workers.

Recommendations and Learning

Points

• Conduct process hazard analy-

sis and implement suitable

layers of protection to mitigate

all identified risks.

• Review all the existing operat-

ing procedures and safety

checklists to ensure they are

written clearly and all the

identified risks (e.g., chemical

incompatibility) have been

highlighted and sufficiently

addressed.

• Provide competency training

to ensure that the workers un-

derstand the process flow and

the risks associated with mix-

ing of incompatible chemicals.

• Ensure positive isolation of

process lines through the use

of double block valves and

bleed with spading to prevent

accidental mixing of incom-

patible chemicals.

• Implement process instrumen-

tation, control and alarm sys-

tems so that key operating

parameters like process tem-

perature and pressure can be

easily monitored.

• Re-design the relief vents for

the worst-case pressure relief

scenario.

• Establish and implement pro-

cedure on the steps and mea-

sures to be taken in the event

of a runaway reaction.

DISCLAIMER: All information contained in this Journal, were obtained from sources, believed to be reliable and are collated, based ontechnical knowledge and experience, currently available with the Editorial Board of SEA (India). While SEA (India) recommends referenceto or use of the contents by its members and subscribers, such reference to or use of contents by its members or subscribers or thirdparties, are purely voluntary and not binding. Therefore the Editorial Board of this Journal or SEA (India) assumes no liability or responsibilitywhatsoever towards any bad or undesired consequences.

14

IN THE NEWS

OSHA issues rule to revise beryllium regulations

A new rule issued by OSHA lowers the allowed levels of a chemical that can cause devastating lung

diseases.

The final beryllium rule reduces the eight-hour permissible exposure limit from the previous 2.0

micrograms per cubic meter (µg/m³) to 0.2 µg/m³. The rule also establishes a short-term exposure

limit of 2.0 µg/m³ over a 15-minute sampling period. The previous exposure limit goes back 40 years.

OSHA has issued three separate sets of rules for general industry, construction and shipyards.

The chemical is highly toxic when beryllium-containing materials are processed in a way that releases

airborne dust, fumes or mist which can damage the lungs.

Recent scientific evidence shows workers who inhale even low levels of airborne beryllium can develop

a lung condition called chronic beryllium disease. Occupational exposure to beryllium has also been

linked the lung cancer. Beryllium is classified as a human carcinogen by the U.S. Department of Health

and Human Services.

At air levels above the eight-hour PEL, employers must take steps to reduce the airborne concentration

of beryllium. The rule also requires additional protections, including personal protective equipment,

medical exams, other medical surveillance and training.

OSHA estimates the rule will save the lives of 94 workers and prevent 46 new cases of beryllium-

related disease each year.

Workers in foundry and smelting operations, fabricating, machining, grinding beryllium metal and alloys,

beryllium oxide ceramics manufacturing, and dental lab work represent the majority of the estimated

62,000 U.S. workers at risk of exposure.

To give companies enough time to meet the new rule's requirements, the regulations come with

staggered compliance dates. The rule will take effect 60 days after its publication date (Jan. 9, 2017)

in the Federal Register. Then employers will have one year from the effective date to implement most

of the standard's provisions. Some exceptions: Change room and shower requirements begin two years

after the effective date; engineering control requirements begin three years after the effective date.

E -Waste rising dangerously

Electronic waste or e-waste is rising sharply across Asia as higher incomes allow hundreds of millions

of people to buy smartphones and other gadgets, with serious consequences for human health and

the environment, according to a UN study .

E-waste in Asia has jumped 63 per cent in five years, the report by the United Nations University said,

as it warned of a need for most nations across the region to improve recycling and disposal methods.

"For many countries that already lack infrastructure for environmentally sound e-waste management,

the increasing volumes are a cause for concern," said Ruediger Kuehr, the report's co-author and head

of the UN University's Sustainable Cycles Programme.

For many years, China and some other parts of Asia have been a dumping ground for discarded

electronics from the developed world, recycling the waste in often unsafe but ultracheap backyard

factories.

But the report said that in recent years, Asia has rapidly emerged as a major source of electronic waste,

due to increasingly affluent consumers buying items such as phones, tablets, refrigerators, personal

computers and televisions.

15

IN THE NEWS

China more than doubled its own generation of e-waste between 2010 and 2015, the period of the

study, according to the report.

Per capita, the worst-offending economy in the region was Hong Kong, with each person in the Chinese

territory generating an average of 21.7kg (47.8 pounds) of e-waste in 2015.

Singapore and Taiwan were also big e-waste dumpers, with just over 19kg per person generated in

2015, according to the study.

Cambodia, Vietnam and the Philippines were among the lowest e-waste generators with an average

of about 1kg for each person.

Meanwhile, improper and illegal e-waste dumping means increased exposure to extremely toxic

chemicals, leading to severe health and environment consequences.

Acids that are used to separate the metals in the electronic products are a particular concern, with

inhalation or exposure to them causing serious health problems.

In the Chinese town of Guiyu, which built its economy on recycling waste from overseas, heavy metal

contamination has turned the air and water toxic, according to a 2014 study by researchers at Shantou

University Medical College.

Children in the town also had high lead levels in their blood, the university study found.

When a study team visited Guiyu in 2014, electronic remnants were strewn in a nearby stream, and

the air was acrid from the burning of plastic, chemicals and circuit boards.

16